U.S. patent number 9,295,805 [Application Number 12/083,349] was granted by the patent office on 2016-03-29 for anti-asphyxia valve assembly for respirator mask.
This patent grant is currently assigned to ResMed Limited. The grantee listed for this patent is Robin Garth Hitchcock, Scott Alexander Howard, Steven John Lubke, Susan Robyn Lynch, Alison Oldenburg, Philip Thomas Stallard, James William Charles Vandyke, David John Worboys. Invention is credited to Robin Garth Hitchcock, Scott Alexander Howard, Steven John Lubke, Susan Robyn Lynch, Alison Oldenburg, Philip Thomas Stallard, James William Charles Vandyke, David John Worboys.
United States Patent |
9,295,805 |
Worboys , et al. |
March 29, 2016 |
Anti-asphyxia valve assembly for respirator mask
Abstract
An elbow assembly for a mask assembly includes an anti-asphyxia
valve (AAV) assembly that may take the form of a box-like frame
work, a drop-in arrangement, or a slot-in arrangement. In each
case, the AAV assembly may include a flap element which is movable
so as to either direct ambient gas/air to the elbow assembly and
thus the patient using the mask assembly, or to allow the passage
of pressurized gas to the patient.
Inventors: |
Worboys; David John (Belrose,
AU), Oldenburg; Alison (Crows Nest, AU),
Stallard; Philip Thomas (Denistone East, AU),
Vandyke; James William Charles (Belrose, AU), Lynch;
Susan Robyn (Bella Vista, AU), Lubke; Steven John
(Stanmore, AU), Howard; Scott Alexander (Harbord,
AU), Hitchcock; Robin Garth (Normanhurst,
AU) |
Applicant: |
Name |
City |
State |
Country |
Type |
Worboys; David John
Oldenburg; Alison
Stallard; Philip Thomas
Vandyke; James William Charles
Lynch; Susan Robyn
Lubke; Steven John
Howard; Scott Alexander
Hitchcock; Robin Garth |
Belrose
Crows Nest
Denistone East
Belrose
Bella Vista
Stanmore
Harbord
Normanhurst |
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A |
AU
AU
AU
AU
AU
AU
AU
AU |
|
|
Assignee: |
ResMed Limited (Bella Vista,
AU)
|
Family
ID: |
37962097 |
Appl.
No.: |
12/083,349 |
Filed: |
January 12, 2006 |
PCT
Filed: |
January 12, 2006 |
PCT No.: |
PCT/AU2006/000031 |
371(c)(1),(2),(4) Date: |
April 10, 2008 |
PCT
Pub. No.: |
WO2007/045008 |
PCT
Pub. Date: |
April 26, 2007 |
Prior Publication Data
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Document
Identifier |
Publication Date |
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US 20090065729 A1 |
Mar 12, 2009 |
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Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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60726699 |
Oct 17, 2005 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A61M
16/06 (20130101); A61M 16/0825 (20140204); A61M
16/208 (20130101); A61M 16/08 (20130101); A61M
16/0816 (20130101); A61M 2205/0216 (20130101); A61M
2205/42 (20130101) |
Current International
Class: |
A61M
16/20 (20060101); A61M 16/06 (20060101); A61M
16/08 (20060101) |
Field of
Search: |
;128/202.27,204.18,205.24,207.16 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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1525895 |
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Apr 2005 |
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EP |
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PCT/AU97/00849 |
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Dec 1997 |
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WO |
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WO 00/38772 |
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Jul 2000 |
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WO |
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WO 02/051486 |
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Jul 2002 |
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WO |
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WO 02/096342 |
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Dec 2002 |
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WO |
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WO 2005/063326 |
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Jul 2005 |
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WO |
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WO 2005/063328 |
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Jul 2005 |
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WO |
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WO 2006/122369 |
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Nov 2006 |
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WO |
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WO 2006/130903 |
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Dec 2006 |
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WO |
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WO 2007/045008 |
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Apr 2007 |
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WO |
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Other References
International Search Report for PCT/AU2006/000031, dated Mar. 23,
2006. cited by applicant .
Office Action Mailed Mar. 28, 2011 in European Application No. 06
704 169.9 (5 pages). cited by applicant .
Third Party Observations Mailed Mar. 25, 2011 in European
Application No. 06 704 169.9 (2 pages). cited by applicant .
European Search Report issued in Ep Appln. No. 06704169.9, mailed
Mar. 4, 2010, 7 pgs. cited by applicant .
Communication issued Mar. 7, 2013 in European Application No. 06
704 169.9 (4 pages). cited by applicant.
|
Primary Examiner: Yu; Justine
Assistant Examiner: Louis; LaToya M
Attorney, Agent or Firm: Nixon & Vanderhye P.C.
Parent Case Text
CROSS REFERENCE TO PRIORITY APPLICATIONS
This application is the U.S. national phase of International
Application No. PCT/AU2006/000031, filed Jan. 12, 2006, which
designated the U.S. and claims the benefit of U.S. Provisional
Application No. 60/726,699, filed Oct. 17, 2005, each of which is
incorporated herein by reference in its entirety.
Claims
What is claimed is:
1. An elbow assembly comprising: an elbow with an opening in a
sidewall of the elbow, the sidewall defining an air flow passage;
the airflow passage extending between a first end of the elbow
configured to receive pressurized gas and a second end of the elbow
configured to be secured to a mask; an anti-asphyxia valve (AAV)
assembly provided to the elbow, the sidewall opening of the elbow
being configured to receive at least a portion of the AAV assembly
so that at least a portion of the AAV assembly is positioned within
the air flow passage; and a support member with an opening to
atmosphere in an outer surface of the support member, the support
member being configured to be secured to a portion of the elbow and
cover the sidewall opening of the elbow, the AAV assembly being
secured to the elbow by the support member and adapted to
selectively close the opening to atmosphere, wherein the support
member is configured so that the outer surface of the support
member is substantially flush with an outer surface of the elbow
when the support member is secured to the portion of the elbow.
2. The elbow assembly of claim 1, wherein the sidewall opening of
the elbow comprises a slot.
3. The elbow assembly of claim 2, wherein the slot is structured to
receive the AAV assembly, and the support member is secured to the
outer surface of the elbow.
4. The elbow assembly of claim 2, wherein the support member is
formed as part of a main wall member of the AAV assembly.
5. The elbow assembly of claim 4, wherein the main wall member and
elbow are secured via a tongue and groove arrangement.
6. The elbow assembly of claim 4, wherein the main wall member
includes a circumferential groove that receives a tongue of the
elbow.
7. The elbow assembly of claim 4, wherein the main wall member is
substantially flush with the outer surface of the elbow.
8. The elbow assembly of claim 1, wherein the AAV assembly includes
a main wall member secured to a cylindrical portion of the
elbow.
9. The elbow assembly of claim 8, wherein the main wall member is
generally planar.
10. The elbow assembly of claim 8, wherein the cylindrical portion
of the elbow includes an extension presenting a substantially
planar surface for securing of the AAV assembly.
11. The elbow assembly of claim 1, wherein the AAV assembly is
positioned adjacent to the opening to atmosphere.
12. The elbow assembly of claim 11, wherein the opening to
atmosphere includes a cylindrical wall member configured to be
selectively engaged by a portion of the AAV assembly.
13. The elbow assembly of claim 1, wherein the support member
comprises an overclip member.
14. The elbow assembly of claim 1, wherein the support member
comprises a push-fit clip member.
15. The elbow assembly of claim 1, wherein the support member
comprises a shroud-type clip member.
16. The elbow assembly of claim 1, wherein the support member and
the AAV assembly are formed as an integral unit.
17. The elbow assembly of claim 1, wherein the support member and
the AAV assembly are secured together by over-molding, gluing
and/or a mechanical lock.
18. The elbow assembly of claim 1, wherein the support member
includes an aperture and the AAV assembly includes a lug which is
received within the aperture.
19. The elbow assembly of claim 1, wherein the AAV assembly is
generally D-shaped in plan view.
20. The elbow assembly of claim 1, wherein the AAV assembly is
generally trapezoidal in profile.
21. The elbow assembly of claim 1, wherein the AAV assembly
includes a base portion and a flap portion hingedly provided to the
base portion.
22. The elbow assembly of claim 21, wherein the hinge is in the
form of a living hinge.
23. The elbow assembly of claim 21, wherein the hinge is formed
along only a portion between the base portion and the flap
portion.
24. The elbow assembly of claim 21, wherein the AAV assembly
includes a rim surrounding the base portion.
25. The elbow assembly of claim 1, wherein the AAV assembly
includes a main wall member having at least one dimension that is
larger than the opening provided in the elbow, the main wall member
being substantially perpendicular to the AAV assembly insertion
direction.
26. The elbow assembly of claim 1, wherein the support member is
generally U-shaped and includes a central wall and side arms, each
of the side arms including a retaining mechanism secured to the
elbow.
27. The elbow assembly of claim 26, wherein the retaining mechanism
includes a lug provided to each arm that is received within a slot
provided on each side of the elbow.
28. The elbow assembly of claim 1, wherein the elbow includes a
first portion adapted to be secured to a frame of a mask assembly
and a second portion structured to receive pressurized gas, and a
first gas path is defined between the first and second
portions.
29. The elbow assembly of claim 28, wherein the opening to
atmosphere is provided between the first and second portions.
30. The elbow assembly of claim 29, further comprising a second gas
path defined between the first portion and the opening to
atmosphere.
31. The elbow assembly of claim 28, wherein the AAV assembly
includes a flap portion to selectively allow either pressurized gas
or ambient air to be directed to the first portion of the
elbow.
32. The elbow assembly of claim 31, wherein the flap portion is
made of silicone or TPE.
33. The elbow assembly of claim 31, wherein the flap portion
comprises liquid silicone rubber.
34. A mask assembly comprising: a frame; and an elbow assembly
according to claim 1.
35. The mask assembly of claim 34, wherein the frame includes a
baffle portion that engages with a seal lip of the AAV assembly
upon assembly of the elbow assembly with the mask frame.
36. The elbow assembly of claim 1, wherein the support member
comprises an overhang portion that provides a finger grip or catch
for removal of the support member from the elbow.
37. The elbow assembly of claim 1, wherein the support member is
adapted to contact the AAV assembly when securing the AAV assembly
to the elbow.
38. The elbow assembly of claim 1, wherein the support member is
securable to the elbow in only one orientation.
39. The elbow assembly of claim 1, wherein the outer surface of the
support member is substantially flush with the outer surface of the
elbow only when the support member is oriented in a predetermined
direction relative to the elbow.
40. The elbow assembly of claim 1, wherein an entirety of the outer
surface of the support member is substantially flush with an outer
surface of the elbow when the support member is secured to the
elbow.
41. The elbow assembly of claim 1, wherein the support member is
generally U-shaped.
Description
FIELD OF THE INVENTION
The present invention relates to an elbow for use with a mask
assembly used for treatment, e.g., of Sleep Disordered Breathing
(SDB) with Continuous Positive Airway Pressure (CPAP) or
Non-Invasive Positive Pressure Ventilation (NPPV).
BACKGROUND OF THE INVENTION
A mask assembly typically includes a relatively rigid shell, e.g.,
a frame, and a patient interface, e.g., a pair of nozzles (which
may be in the form of nasal pillows, nasal prongs, cannulae, or
nasal puffs) or a cushion (nasal or full-face), that is supported
by the rigid shell and structured to deliver pressurized gas to the
patient or user in a comfortable, sealed manner. The mask assembly
is usually held in place using a headgear assembly.
In some applications, there may be a clinical requirement to
provide the mask assembly with one or more safety devices, such as
means for CO.sub.2 washout, vents, anti-asphyxia valves and the
like. In some cases, these additional components are assembled
between the gas delivery conduit and the mask assembly. Problems
with prior art assemblies may include:
(a) inadvertent assembly without one or more of the safety
devices;
(b) incorrect assembly/alignment; and/or
(c) incorrect re-assembly following inadvertent dis-assembly during
the course of treatment.
Flow generators typically deliver pressurized breathable gas (air)
to a patient wearing the mask assembly. In CPAP treatment, gas is
delivered to the patient's airways at about 2-30 cm H.sub.20 above
atmospheric pressure. The flow generator is generally connected to
flexible tubing (air delivery tube) that is secured to the mask
assembly worn by the patient. If the flow generator's operation is
interrupted as a result of power outage or other
mechanical/electrical failure, there may be a significant build up
of carbon dioxide in the mask as the patient's exhaled air is not
washed out of outlet vents that are usually provided to the mask
assembly. This may present a health risk to the patient.
Several patents have addressed this risk, e.g., by use of a safely
valve for gas or air delivery mask assemblies. See, e.g., U.S. Pat.
No. 3,796,216 to Schwarz, and U.S. Pat. No. 5,438,981 to Starr et
al., as well as PCT international application no.
PCT/AU97/00849.
BRIEF SUMMARY OF THE INVENTION
According to one aspect of the invention, there is provided an
elbow assembly comprising an elbow; an anti-asphyxia valve (AAV)
assembly provided to the elbow; and a clip member or portion to
secure the AAV assembly to the elbow
According to yet another aspect of the invention, there is provided
an elbow assembly for a mask, comprising: an elbow having a first
portion structured to engage with a mask frame and a second portion
structured to receive pressurized gas; a first gas path defined
between the first and the second portions; a port in communication
with atmosphere and in selective communication with the first
portion of the elbow; a second gas path defined between the first
portion and the port; and an anti-asphyxia valve (AAV) assembly,
said AAV assembly including a flap portion and a frame assembly
integrally supporting the flap portion, the flap portion being
movable to selectively open and close the port, wherein said flap
portion assumes a closed position when pressurized gas less than or
equal to a predetermined threshold is delivered to the second
portion of the elbow, in which case the port can communicate with
the first portion via the second gas path, and said flap assumes an
open position when pressurized gas above the predetermined
threshold is delivered to the second portion, in which case the
flap portion seals the port and the first portion is in
communication with the second portion via the first gas path.
According to still another aspect of the present invention, there
is provided a mask assembly comprising a frame; an elbow provided
to the frame; and an anti-asphyxia valve (AAV) assembly secured
within the elbow upon assembly of the elbow to the frame.
According to yet another embodiment of the present invention, there
is provided an elbow assembly comprising an elbow, the elbow having
a first portion adapted to be secured to a mask and a second
portion adapted to receive pressurized gas, the first and the
second portions having connection structure allowing selective
connection and disconnection between the first and second portions,
the connection structure including a pair of resilient arms
provided on one of the first and second portions and a flange
provided on the other of the first and second portions, each of the
arms including a claw to lock with the flange; and an anti-asphyxia
valve (AAV) assembly provided within the elbow and sandwiched
between the first and second portions.
Another aspect of the present invention relates to a mask assembly
including a frame, an elbow provided to the frame, and an elbow to
frame assembly mechanism to releasably assemble the elbow to the
frame. The elbow to frame assembly mechanism includes an elbow to
frame adaptor that attaches to the frame and provides a flanged
collar member onto which the elbow can be releasably assembled.
Another aspect of the present invention relates to a mask assembly
including a frame, an elbow having one end provided to the frame
and an opposite end provided to a swivel, and an elbow-to-swivel
adaptor to connect the elbow to the swivel. The elbow-to-swivel
adaptor includes a snap-fit tab to connect the elbow-to-swivel
adaptor to the elbow with a snap-fit.
Another aspect of the present invention relates to a mask assembly
including a frame, an elbow provided to the frame, and an
integrated elbow seal and port cap assembly provided between the
elbow and the frame. The elbow seal and port cap assembly includes
an elbow seal to provide a seal between the elbow and the frame and
a port cap to releasably connect to a port provided to the
frame.
Other aspects, features, and advantages of this invention will
become apparent from the following detailed description when taken
in conjunction with the accompanying drawings, which are a part of
this disclosure and which illustrate, by way of example, principles
of this invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings facilitate an understanding of the
various embodiments of this invention. In such drawings:
FIG. 1 is an exploded, perspective view of an elbow assembly
according to one embodiment of the present invention;
FIG. 2 is a cross-sectional view of the elbow assembly of FIG. 1 in
the assembled condition;
FIG. 3 is a rear view of the elbow assembly of FIG. 1;
FIG. 4 is a front perspective view of the AAV assembly of FIG.
1;
FIG. 5 is a reverse perspective view thereof;
FIG. 6 is a side elevation view thereof;
FIG. 7 is a front view thereof;
FIG. 8 is a rear view thereof;
FIG. 9 is a cross-sectional view thereof;
FIG. 10 is a perspective view of an elbow assembly according to
another embodiment of the present invention;
FIG. 11 is a reverse perspective view thereof;
FIG. 12 is a cross-sectional view thereof;
FIGS. 13 and 14 are exploded, perspective views thereof;
FIG. 15 is a perspective view of a mask assembly according to yet
another embodiment of the present invention;
FIG. 16 is a side view thereof;
FIG. 17 is a cross-sectional view thereof;
FIG. 18 is a cross-sectional view of an elbow assembly according to
still another embodiment of the present invention;
FIG. 19 is a perspective view of the elbow without the AAV
assembly;
FIG. 20 is a perspective view of the AAV assembly shown in FIG.
18;
FIG. 21 is another perspective view of the AAV assembly shown in
FIG. 18;
FIG. 22 is a bottom view thereof;
FIG. 23 is a perspective view of an elbow assembly according to
another embodiment of the present invention;
FIG. 24 is a reverse perspective view thereof;
FIG. 25 is a cross-sectional view thereof;
FIG. 26 is a cross-sectional view of an elbow according to another
embodiment of the present invention;
FIG. 27 is a perspective view thereof;
FIG. 28 is a cross-sectional view of an AAV assembly for use with
the elbow shown in FIGS. 27 and 28;
FIG. 29 is a perspective view thereof;
FIG. 30 is a perspective view of the elbow assembly;
FIG. 31 is a reverse perspective view thereof;
FIG. 32 is a side elevation view thereof;
FIG. 33 is a cross-sectional view thereof;
FIG. 34 is an exploded perspective view of an elbow assembly
according to another embodiment of the present invention;
FIG. 35 is an assembled view thereof, from a different
perspective;
FIG. 36 is a cross-sectional view thereof;
FIG. 37 is a perspective view of the elbow without the AAV
assembly;
FIG. 38 is a perspective view of the clip member shown in FIGS.
34-36;
FIG. 39 is a plan view of the AAV assembly in isolation;
FIG. 40 is a perspective view of a clip/AAV assembly;
FIG. 41 is an exploded perspective view thereof;
FIG. 42 is a perspective view of an over-molded clip/AAV assembly
according to an embodiment of the present invention;
FIG. 43 is a cross-sectional view of the AAV assembly shown in FIG.
41;
FIGS. 44-47 illustrate several different embodiments of AAV
assemblies having different hinge arrangements;
FIG. 48 is a perspective view of an elbow assembly according to
another embodiment of the present invention;
FIG. 49 is cross-sectional view thereof;
FIG. 50 is a perspective view of an elbow assembly according to
another embodiment of the present invention;
FIG. 51 is a side view thereof;
FIG. 52 is a reverse perspective view thereof;
FIG. 53 is a cross-sectional view of an elbow assembly according to
another embodiment of the present invention;
FIG. 54 is a cross-sectional view thereof from a different
perspective;
FIG. 55 is rear perspective view thereof;
FIG. 56 is an exploded perspective view of an elbow assembly
according to yet another embodiment of the present invention;
FIG. 57 is a perspective view thereof in an assembled
condition;
FIG. 58 is cross-sectional view thereof;
FIG. 59 is perspective view of a portion of an elbow assembly on a
conduit having an AAV assembly according to an embodiment of the
present invention;
FIG. 60 is a top view thereof;
FIG. 61 is cross-sectional view thereof;
FIGS. 62-67 illustrate alternative embodiments of an AAV assembly
and clip member;
FIGS. 68-89 show various views of an elbow assembly according to
another embodiment of the present invention;
FIGS. 90-111 show various views of an elbow assembly according to
another embodiment of the present invention;
FIGS. 112-133 show various views of an elbow assembly according to
another embodiment of the present invention;
FIGS. 134-154 show various views of an elbow assembly according to
another embodiment of the present invention;
FIGS. 155-156 are exploded views illustrating the elbow of FIGS.
134-154 being assembled between a mask frame and a swivel
joint;
FIGS. 157-161 show various views of the elbow of FIGS. 134-154
connected between the mask frame and the swivel joint of FIGS.
155-156;
FIG. 162 is an exploded perspective view of an elbow assembly
according to an embodiment of the present invention;
FIG. 163 is an assembled view thereof;
FIG. 164 is as side elevation view thereof;
FIG. 165 is an exploded view of a mask assembly according to an
embodiment of the present invention;
FIG. 166 is cross-sectional depiction thereof;
FIG. 167 is an exploded view of the elbow assembly thereof;
FIG. 168 is a cross-sectional view thereof;
FIG. 169 is a cross-sectional view of an elbow assembly according
to an embodiment of the present invention;
FIG. 170 is a top view of an AAV assembly for use in the assembly
of FIG. 169;
FIG. 171 is a perspective view thereof with the AAV assembly with
the flap portion in an upright position;
FIGS. 172-173 illustrate an elbow assembly with a drop-in AAV
assembly according to another embodiment of the present
invention;
FIGS. 174-185 illustrate an elbow to frame assembly mechanism
according to an embodiment of the present invention;
FIGS. 186-203 illustrate an elbow to frame assembly mechanism
according to another embodiment of the present invention;
FIGS. 204-221 illustrate an elbow to frame assembly mechanism
according to another embodiment of the present invention;
FIGS. 222-233 illustrate an elbow to frame assembly mechanism
according to another embodiment of the present invention;
FIGS. 234-251 illustrate an elbow to frame assembly mechanism
according to another embodiment of the present invention;
FIGS. 252-269 illustrate an elbow to frame assembly mechanism
according to another embodiment of the present invention;
FIGS. 270-281 illustrate an elbow to frame assembly mechanism
according to another embodiment of the present invention; and
FIGS. 282-299 illustrate an elbow to frame assembly mechanism
according to still another embodiment of the present invention.
DETAILED DESCRIPTION OF ILLUSTRATED EMBODIMENTS
The following description is provided in relation to several
embodiments which may share common characteristics and features. It
is understood that one or more features of any one embodiment may
be combinable with one or more features of the other
embodiments.
1.0 "Letter Box" AAV Assembly
1.1 First Embodiment
FIGS. 1-9 illustrate an elbow assembly 5 according to a first
embodiment of the invention. As shown in FIG. 1, the elbow assembly
5 generally comprises an elbow 10 and an anti-asphyxia valve 15
(AAV) assembly.
The elbow has a first portion 20 and a second portion 25. The first
portion 20 is connected or otherwise provided to a mask frame 30 of
a mask assembly (not shown in FIG. 1), e.g., in a snap-fit manner,
as is known from U.S. patent application publication no.
2003/0196656 incorporated herein by reference. Only a portion of
the frame of the mask assembly is shown in FIG. 1. The frame
includes a flanged collar member 35 onto which the first portion 20
of the elbow 10 can be releasably connected.
The second portion 25 is intended to receive pressurized gas from a
source of pressurized gas (e.g., air from a CPAP machine or other
ventilation device). The second portion 25 typically will be
provided with a swivel joint which in turn is connected to an air
delivery tube in communication with a flow generator. However, the
second portion 25 may have other connections, e.g., tapered joint
to allow attachment to a short tube. The elbow 10 can be made from
a relatively rigid material, such as polycarbonate or other
plastic.
The cross-section of FIG. 2 shows the assembled condition of the
AAV assembly 15 and the elbow 10. The elbow 10 includes a port 40
that may be selectively closed by a flap portion 45 of the AAV
assembly. If the pressurized gas provided to the second portion 25
of the elbow 10 is of sufficient magnitude, the flap portion 45
will raise to the block off the port 40. In this case, pressurized
gas will be guided from the second portion 25 toward the first
portion 20, for delivery to the mask and the patient's airways. If
pressurized gas is not delivered due to a power outage and/or
mechanical/electrical failure, the flap portion 45 will remain in
the "rest" position shown in FIG. 2, so that the patient can
breathe in ambient air and exhale through the port 40. FIG. 3 shows
that the port includes a cross member 50 provided as part of the
elbow.
The AAV assembly can be inserted from the direction of the frame 30
to elbow 10 (right to left in FIG. 1). Accordingly, the AAV
assembly is sandwiched in place when the elbow assembly (elbow and
AAV assembly) are connected to the frame. This helps avoid
inadvertent disassembly.
The elbow 10 includes internal structure to hold the AAV assembly
15 in position. More specifically, the AAV assembly 15 includes a
frame assembly 55 which in this embodiment generally resembles a
"letter box" or "mail box", including an main wall member 60, side
wall members 65 and a base portion 70 that supports the flap
portion 45. The side wall members 65 are tapered so as to generally
match the interior contour of the elbow 10.
The main wall member 60 includes an outer rim 75 including a
protruding bead that is intended to be received in a corresponding
groove 80 in the elbow 10. The AAV assembly is easily disassembled
once the elbow is removed from the frame. The AAV assembly is a
relatively large, three dimensional component, which reduces the
chance that it will become lost. Its size and shape also
facilitates finding, holding and assembling the AAV assembly.
Moreover, the AAV assembly can only be assembled in one manner. The
cross member 50 is provided on the elbow to prevent the flap
portion from being over-pressurized. The cross member 50 also
prevents inadvertent AAV assembly, e.g., pushing through the
atmospheric hole, and blocking the atmospheric hole which could
cause inadvertent deactivation.
The main wall member 60 also includes an aperture 85 defined by a
circumferential seal lip 90 that is intended to sealingly engage a
portion of the mask frame upon assembly (see FIG. 17, discussed
more below). The AAV assembly therefore combines the typical
function of an AAV assembly with that of sealing the elbow to frame
connection. Sealing in this manner may provide one or more of the
following advantages: prevent/reduce elbow/frame rattling; provide
high quality feel; prevent/reduce overly free rotation; dampen
vibration; prevent/reduce squeak; reduce inadvertent (and often
variable) leak; and/or reduce tolerance requirements for the "hard"
components (e.g., frame, elbow, etc.).
The elbow also includes an internal shoulder 95 that supports the
AAV assembly. In this embodiment, the shoulder supports the base
portion 70 of the AAV assembly. The flap portion 45 is movably
provided, e.g., hingedly connected, to the base portion in an
orientation such that the flap portion pivots at a point just below
the port 40. This pivoting occurs at a position which is opposite
to the main wall member 60. The free end 100 of the flap portion is
also supported by the shoulder of the elbow, as shown in FIG.
2.
FIGS. 4-9 are enlarged views of the AAV assembly and show further
details of the frame assembly, flap portion, base portion, main
wall member and side wall members. As seen in FIGS. 4-6, the AAV
assembly includes a slightly curved portion which is intended to
match the shape of the cylindrical portion of the elbow where the
AAV assembly is supported. Further, FIG. 6 shows the tapered side
view which is intended to match the shape of the upper portion of
the elbow. FIG. 9 shows in more detail the seal lip 90 as well as
the connection 105 (e.g., an integral or living hinge) between the
flap portion and the base portion. In the illustrated embodiment,
the connection 105 is thinner than the flap portion 45, e.g.,
approximately 0.5 mm. Generally, the AAV assembly forms part of the
internal geometry of the elbow. Furthermore, the AAV assembly can
perform the functions of an anti-asphyxia valve, elbow-to-frame
seal and oxygen diverter valve.
All components of the AAV assembly are formed of a single piece of
material in this embodiment. The AAV assembly is preferably formed
from a silicone based material, such as molded liquid silicone
rubber (LSR). This design suits an open and shut tool with one
single core, form which the AAV assembly can be de-molded. However,
the AAV assembly may be formed by more than one part of silicone
and/or rigid material, e.g., over-molding, mechanical
interlock.
1.2 Second Embodiment
FIGS. 10-14 illustrate an elbow assembly 5 according to another
embodiment of the invention. This embodiment is similar to the
first embodiment, but includes a few changes. The following will
provide a description of the main differences between the
embodiments, although other differences may be apparent to the
skilled artisan. For example, the port 40 shown in FIG. 10 has a
slightly different configuration.
The AAV assembly has a very similar manner of operation and
structure. However, the AAV assembly is secured in the elbow in a
slightly different manner. In particular, while the AAV assembly in
the first embodiment is secured (in part) using a bead that
protrudes from an outer circumference 75 of the AAV assembly into a
groove 80 in the elbow, the AAV assembly in FIG. 12 includes a
shoulder 110 that engages with an edge 115 of the elbow 10. The
lower end 120 of the main wall member 60 is supported by a surface
125 of the elbow.
1.3 Third Embodiment
FIGS. 15-17 illustrate an mask assembly according to yet another
embodiment of the present invention. In this embodiment, elbow
assembly 5 is similar to those described above, but FIGS. 15-17
show the elbow assembly connected to a sample mask frame 130. FIG.
17 is a cross-sectional view showing the interconnection between
the frame and the elbow. The flanged collar 35 of the frame 130 is
shown in its locked orientation relative to the elbow assembly.
Further, the frame 130 includes a baffle portion 135 having an
exterior surface that is sealingly engaged by the seal member 90,
upon assembly. The baffle portion 135 may extend into the breathing
chamber 140 of the mask assembly.
1.4 Fourth Embodiment
FIGS. 18-22 illustrate an elbow assembly 5 according to yet another
embodiment of the present invention. The elbow as shown in FIG. 19
includes a port 40 that is generally rectangular in shape.
Accordingly, the AAV assembly 15 also has a frame assembly having a
generally rectangular box-like shape. The frame assembly includes,
in addition to an main wall portion 60, side wall portions 65, a
flap portion 45 and a base portion 70, a top wall portion 145. The
top wall portion 145 includes a stop member 150 limiting the upward
maximum amount of movement of the flap portion 45. Main wall
portion 60 includes one or more cross members 50.
AAV assembly in this embodiment can be assembled from either the
port side or the first portion of the elbow closest to the frame.
AAV assembly can be held in place relative to the elbow using
friction, and the assembly may also include additional mechanical
locking structure and/or glue. The main wall portion 60 is
positioned within the port and is generally flush with the exterior
surface 155 of the elbow.
FIGS. 20-22 show the AAV assembly in isolation where additional
detail can be seen.
1.5 Fifth Embodiment
FIGS. 23-25 illustrate an elbow assembly 5 according to another
embodiment of the present invention. The AAV assembly 15 and the
elbow 10 are connected using a tongue and groove arrangement. In
this example, the elbow 10 includes a tongue 160 and the AAV
assembly includes a groove 165. Once engaged, a portion 170 of the
AAV assembly extends beyond the rear end of the elbow 10. The
portion 170 is generally cylindrical and matches the shape of the
cylindrical portion of the elbow.
The AAV assembly 15 is assembled from the port side toward the
first portion of the frame. The AAV assembly includes a top portion
that is generally contoured to match the tapered top portion if the
interior of the elbow. The top portion includes a stop portion 175
to limit the maximum travel of the flap portion 45. The AAV
assembly has a forward portion 180 oriented towards the frame that
may sealingly engage a portion of the frame upon connection.
1.6 Sixth Embodiment
FIGS. 26-33 illustrate an elbow assembly according to a further
embodiment of the invention. This embodiment may not technically
fall under the heading of "`Letter Box` AAV assembly", but is being
grouped herewith since there are similarities with the previous
embodiment.
FIGS. 26-27 show the elbow 10, FIGS. 28-29 show the AAV assembly
15, and FIGS. 30-33 show the elbow/AAV assembly 5. The AAV assembly
15 and elbow 10 are connected using a tongue and groove 185
arrangement, where the AAV assembly includes a groove that receives
a tongue or flange 190 of the elbow. As shown in FIG. 28, the AAV
assembly includes a flap portion 45 and defines the port 40. The
flap portion 45 rests on interior features of the elbow, as shown
in FIG. 33.
2.0 Slot-In AAV Assembly
2.1 First Embodiment
FIGS. 34-47 are directed towards an elbow assembly 5 according to
another embodiment of the present invention. Elbow assembly
includes an elbow 10, an AAV assembly 15 and a clip member or
portion 200 to secure the AAV assembly 15 to the elbow 10.
Elbow 10 includes a first portion 20 and a second portion 25, as
described above. Elbow also includes a slot 205, just below the
port 40, that is structured to receive the AAV assembly 15.
As best shown in FIG. 36, the slot 205 is formed by a ledge. The
ledge supports the AAV assembly 15 during use, guides assembly and
disassembly, and prevents misassembly (i.e., back to front). That
is, the upper ridge and lower surface in the elbow form a housing
which acts as a lead-in for the AAV assembly 15 and supports the
outer edge of the AAV assembly 15 in use.
AAV assembly 15 is preferably molded LSR. AAV assembly includes an
main wall member 60 and a base portion 70 that extends away from
the main wall member 60. A flap portion 45 is hingedly connected to
the main wall member (FIG. 36). AAV assembly is generally D-shaped
in profile (FIG. 39), and generally trapezoidal from the side (FIG.
36). This helps to prevent assembly in the wrong way and ensures
assembly in the correct manner.
The clip member 200 has a generally U-shape. Clip member 200 has a
central wall 210 and two arms 215. Each arm 215 includes a
protrusion 220 to lockingly engage with a corresponding recess 225
formed in the sides of the elbow 10. The assembled condition of the
elbow/AAV assembly is shown in FIGS. 35 and 36. In FIG. 36, it can
be seen that the flap portion 45 can move to selectively cover the
port 40, depending on the presence of pressurized gas p.
Both the clip member 200 and AAV assembly 15 have symmetrical
shapes which allows both of them to be properly assembled in either
vertical orientation, i.e., the clip member can be turned upside
down without affecting operation. If the flap portion 45 gets
caught upon assembly, the clip member will not slot-in, which
provides for fail safe assembly. When the clip member 200 is fully
located with in slot 205 with the arms 215 locked in place, an
audible and/or tactile `click` is observed, confirming full
assembly--to act as feedback for the user.
The outer part (or base portion 70) of the flap portion 45 may be
solid (e.g., part of overmold). The gap 218 between the outer part
70 and the moving flap portion 45 should be relatively small, e.g.,
about 0.5-1 mm or about 0.75 nm, to prevent oxygen or other gases
from being delivered to the patient from the flow generator, and/or
to prevent rebreathed CO.sub.2 accumulating in the tube, when the
flap portion 45 is not activated.
The interior surface 225 of the elbow 10 that engages the flap
portion 45 is preferably flat to provide an improved sealing
mechanism by preventing inadvertent disassembly through pressure on
the reverse side. The flat surface also assists in reducing
inadvertent deactivation or flutter, and helps the flap portion to
activate at a lower pressure. The flap portion moves through an
angle of about 20-90 degrees, 50-70 degrees, or about 60 degrees,
by engaging the flat surface at that angle. This angle helps entry
impedance of the air to the mask and also improves the compactness
of the design. The flat surface also promotes smooth flow entering
the mask and reduces noise and turbulence.
In the example shown in FIG. 36, the elbow assembly is dimensioned
as follows:
Surface area of the flap portion: about 250 mm.sup.2--area promotes
activation at lower pressures
Area of port (or atmospheric hole): about 100 mm.sup.2--maximize
size of hole to accommodate the flap portion and allow area for
sealing (may also be suitably sized to activate at lower
pressures)
Angle of port: greater than 45 degrees; about 60 degrees
Overlap of flap portion over port: about 1.4-2.9 mm (varies with
position)
Height of flap portion: about 1 mm
Hinge height: 0.1-0.9 mm, preferably about 0.4-0.6 or about 0.5
mm
Hinge length: about 5-20 mm, preferably about 15-17 mm
It should again be noted that these dimensions are examples only,
and the dimensions could be modified depending on application. For
example, the dimensions could vary up to .+-.20% of the values
provided.
FIG. 37 shows the elbow in isolation, in which the slot 205 is
clearly visible. As illustrated, a bead feature 206 is provided
outside the slot 205. The bead feature 206 provides a sealing
feature between the elbow and the wall member 60 of the AAV
assembly 15. FIG. 38 shows the clip member 200 in isolation, while
FIG. 39 shows the AAV assembly 15 in isolation.
The AAV assembly 15 and the clip member 200 may be made separately
and assembled as described above or the clip member and AAV
assembly may be initially combined into a sub-assembly and then
inserted into the slot of the elbow. Combining of the AAV assembly
and the clip member can be achieved using various expedients, such
as over-molding, gluing, mechanical lock, etc. The clip member may
be an overclip member or a push fit clip, e.g., one that clips to
internal structure of the elbow.
One example of a mechanical lock method is shown in FIGS. 40-41. In
this embodiment, the main wall member 60 of the AAV assembly
includes a locking leg 230 integrally molded with the AAV assembly.
The AAV assembly, including the locking leg, is preferably made
from LSR. The locking leg includes an enlarged head portion that
protrudes through a hole 235 in the central wall of the clip. The
head portion expands once through the hole to lock the AAV assembly
to the clip. FIG. 43 shows a cross section of the clip member with
the locking leg.
FIG. 42 shows an example of an over-molded clip/AAV assembly. This
is a relatively permanent connection method, unlike the mechanical
connection described in relation to FIGS. 40-41.
FIGS. 44-47 show various embodiments in which there is a variation
on the hinge 240. The length of the hinge 240 modifies the
activation/deactivation pressure. The hinge could be straight
across, with gaps at the ends, or a gap in the middle. While none
of these embodiments use a locking leg, it is to be understood that
each could be formed with such. FIG. 44 is the case where the hinge
between the flap portion and the main wall member extends over
substantially the entire length of the flap portion. FIG. 45
includes a small gap near the central portion of the flap portion.
FIG. 46 includes a large central hinged portion, while the end
portions include gaps. FIG. 47 is the opposite arrangement where
the hinges are only formed along the end portions. It is to be
understood that "hingedly connected" also encompasses the situation
where the flap portion merely bends relative to its support.
Moreover, the flap portion could be arranged to move in a more
linear fashion, and is thus not limited to bending or pivoting
movement.
2.2 Second Embodiment
FIGS. 48-49 show an elbow assembly 5 according to an alternative
embodiment of the present invention. In particular, cross-sectional
FIG. 49 illustrates how the AAV assembly 15 is seated relative to
the elbow 10. The elbow 10 includes a shoulder 245 that supports
the flanged portion 250 of main wall member 60 such that the
flanged portion is flush with the outer surface of the elbow. The
clip member 200 is positioned over the AAV assembly to hold it in
place relative to the elbow. The clip member and AAV assembly may
be connected via a tongue and groove arrangement or a snapping
arrangement. The clip member may "snap" in place to provide
confirmation of correct assembly to the user.
2.3 Third Embodiment
FIGS. 50-52 show an elbow assembly according to yet another
embodiment of the present invention. This embodiment is similar to
the above embodiment but includes a shroud-like clip 200.
2.4 Fourth Embodiment
FIGS. 53-55 illustrate an elbow assembly according to still another
embodiment of the present invention. In this embodiment, the clip
member or portion 200 is formed as part of the AAV assembly 15,
thus eliminating a part. The main wall member 60 includes a clip
portion 200 that is directly connected to the elbow 10 by inserting
a rim 252 of the elbow surrounding the slot 205 into a
correspondingly shaped groove 255 formed in the edge of the main
wall member. The AAV assembly is made of LSR which allows it to be
compressed into the slot formed in the elbow. The resiliency of the
AAV assembly returns it to its original shape whereby it will flex
into locking relationship with the slot. The outer surface 260 of
the main wall member is substantially flush with the outer surface
265 of the elbow, as seen in FIGS. 53-55.
2.5 Fifth Embodiment
FIGS. 56-58 show an elbow assembly 5 according to another
embodiment of the present invention. The elbow assembly 5 includes
an elbow and an AAV assembly. The elbow includes a port 40 that
includes a cylindrical conduit 266 leading to the interior of the
elbow. The conduit forms an end portion intended to form a
generally flat engagement portion with flap portion 45, when
activated. The elbow includes molded extension members 270, just
below the port, that form an attachment interface 275 for
engagement with the AAV assembly. The attachment interface 275
includes a flanged portion 280 that extends about the periphery of
the slot. The flanged portion engages with a groove 290 formed in
the main wall member 60.
The AAV assembly is generally wedge shaped and slides in
drawer-like fashion into the slot 205 of the elbow. The surrounding
portion 295 of the AAV assembly is generally hoop shaped and may
include an internal ledge 300 to support the flap portion in the
rest position. The inside surface of the elbow may include a
shoulder 305 or ledge to support the lower portion of the hoop
shaped portion.
2.6 Sixth Embodiment
FIGS. 59-61 show a portion of an elbow assembly 5 according to
another embodiment of the present invention. This embodiment is
similar to the prior embodiment, but the cylindrical portion 310 of
the elbow does not include extension members that present a
generally flat attachment portion for the AAV assembly 15. Instead,
the main wall member has a curved profile so that it can be locked
with the flanged portion 315 formed on the cylindrical portion 310
of the elbow. The main wall member 60 can be preformed in a curved
manner, or it can simply bend upon engagement with the elbow.
2.7 Seventh Embodiment
FIGS. 62-67 illustrate three alternative embodiments of an AAV
assembly 15 and clip member 200 for insertion into the slot of an
elbow. In each of the embodiments, the AAV assembly 15 and clip
member 200 may be independent parts, permanently joined (e.g.,
glued, overmolded), or semi-permanently joined (e.g., mechanical
interlock). Also, the shape of the AAV assembly 15 and clip member
200 may be modified in other suitable manners. In addition, some
combination of features of the three alternative embodiments may be
used.
FIGS. 62 and 63 illustrate an embodiment that provides a clip
member 200 that is relatively rigid. This arrangement provides
additional protection of the AAV assembly 15 and limits incorrect
assembly modes. Also, the relatively rigid support provides a more
robust appearance.
FIGS. 64 and 65 illustrate an embodiment that provides a clip
member 200 with a relatively flexible base member 70. This
arrangement is relatively easier to assemble into clip than the
rigid support, and is relatively larger to provide a perception of
robustness. In addition, there is less chance of damaging the hinge
supporting the flat portion 45 (compared to the rigid support).
FIGS. 66 and 67 illustrate an embodiment that provides an AAV
assembly 15 with an open flap portion 45. This arrangement is
relatively easier to assemble than rigid and flexible supports, and
limits incorrect assembly modes. Also, this arrangement allows a
more streamlined elbow design.
2.8 Eighth Embodiment
FIGS. 68-89 illustrate an elbow assembly 5 according to another
embodiment of the present invention. As illustrated, the elbow
assembly 5 includes an elbow 10, an AAV assembly 15, and a clip
member 200 to secure the AAV assembly 15 to the elbow 10.
The elbow 10 includes a first portion 404 provided to the mask
frame and a second portion 406 provided to a swivel joint connected
to an air delivery tube. The first portion 404 includes snap-fit
tabs 408, e.g., six tabs, to connect the first portion 404 to the
mask frame with a snap-fit. However, more or less snap-fit tabs may
be used, e.g., 2-10 tabs. A unique mold/tool configuration may be
used to produce the snap-fit tabs 408 which are less prone to
molding stress build-up and therefore less likely to break off the
elbow. Localized stress during the molding process may be reduced
by the incorporation of radii on internal edges. Two of the
snap-fit tabs 408, e.g., upper and lower tabs, are more elongated
and extend into the mask frame when connected. These elongated tabs
408 may be squeezed to release the elbow 10 from the mask
frame.
The second portion 406 includes snap-fit tabs 410, e.g., six tabs,
to connect the second portion 406 to the swivel joint. A unique
mold/tool configuration may be used to produce the snap-fit tabs
410 which are less prone to molding stress build-up and therefore
less likely to break off the elbow. Localized stress during the
molding process may be reduced by the incorporation of radii on
internal edges. The snap-fit diameter at the second portion 406 is
smaller than the snap-fit diameter at the first portion 404 to
prevent incorrect assembly. Also, the retention force of the
snap-fit at the second portion 406 is smaller than the retention
force of the snap-fit at the first portion 404. This arrangement
provides a quick-release safety and convenience feature.
Annular rings 412, e.g., three rings, are provided on the second
portion 406 for improved seal with the swivel joint and improved
manufacturability.
The elbow 10 also includes a slot 414 to receive the AAV assembly
15, a port 416 that is selectively closed by the flap portion 45 of
the AAV assembly 15, and two recesses 418 for attaching the clip
member 200 with a snap-fit. The slot 414 has a thin bead around its
opening which forms a line contact sealing region to prevent air
leak.
The AAV assembly 15 interlocks with the clip member 200 to provide
a sub-assembly that is removably attached to the elbow 10 with a
snap-fit. Specifically, the AAV assembly 15, e.g., constructed of
flexible silicone, includes a protrusion 420 that removably
interlocks with a slot 422 provided on the clip member 200, e.g.,
constructed of rigid plastic. The clip member 200 includes two tabs
424 that interlock with respective recesses 418 provided to the
elbow 10.
FIG. 68 is an exploded view of the elbow assembly 5, FIGS. 69-75
are assembled views of the elbow assembly 5, FIGS. 76-82 are
isolated views of the elbow 10, and FIGS. 83-89 are isolated views
of the clip member 200.
2.9 Ninth Embodiment
FIGS. 90-111 illustrate an elbow assembly 5 according to another
embodiment of the present invention. As illustrated, the elbow
assembly 5 includes an elbow 10, an AAV assembly 15, and a clip
member 200 to secure the AAV assembly 15 to the elbow 10.
This embodiment is similar to the elbow assembly 5 shown in FIGS.
68-89. In contrast, the elbow assembly 5 of FIGS. 90-111 includes
two rigid tabs 430 integrally molded with the elbow 10 to prevent
over-extension of the elongated snap-fit tabs 408 during
disassembly and thereby prevent their breakage. Also, the clip
member 200 has a shroud-like configuration with a hole 43' that
aligns with the port 416.
FIG. 90 is an exploded view of the elbow assembly 5, FIGS. 91-97
are assembled views of the elbow assembly 5, FIGS. 98-104 are
isolated views of the elbow 10, and FIGS. 105-111 are isolated
views of the clip member 200.
2.10 Tenth Embodiment
FIGS. 112-133 illustrate an elbow assembly 5 according to another
embodiment of the present invention. As illustrated, the elbow
assembly 5 includes an elbow 10, an AAV assembly 15, and a clip
member 200 to secure the AAV assembly 15 to the elbow 10.
This embodiment is similar to the elbow assembly 5 shown in FIGS.
90-111. Annular rings 413 and 412 are provided on first and second
end portions 404, 406, respectively, for an improved seal with the
frame and swivel joint, respectively, and improved
manufacturability. In contrast, the clip member 200 of FIGS.
112-133 includes a more elongated shroud-like configuration. Also,
the first portion 404 does not include elongated tabs 408 aligned
with rigid tabs 430. In addition, the elbow of FIGS. 112-133
includes protrusions 415 rather than a recess which interact with
protrusions on the clip member 200. The elongated shroud-like
configuration of the clip member 200 provides a visual indicator to
aid correct assembly of the clip member to the elbow 10.
FIG. 112 is an exploded view of the elbow assembly 5, FIGS. 113-119
are assembled views of the elbow assembly 5, FIGS. 120-126 are
isolated views of the elbow 10, and FIGS. 127-133 are isolated
views of the clip member 200. The clip member 200 is relatively
large and is easier for patients with low dexterity to manipulate.
Further, if dropped, it is easier to locate, particularly in the
dark.
2.11 Eleventh Embodiment
FIGS. 134-154 illustrate an elbow assembly 5 according to another
embodiment of the present invention. As illustrated, the elbow
assembly 5 includes an elbow 10, an AAV assembly 15, and a clip
member 200 to secure the AAV assembly 15 to the elbow 10.
This embodiment is similar to the elbow assembly 5 shown in FIGS.
68-89. In contrast, the elbow assembly 5 of FIGS. 134-154 is
structured such that the clip member 200 is substantially flush
with a surface 435 surrounding the port 416. Also, the first
portion 404 does not include elongated tabs 408. The port 416 also
has a central rib 436 to prevent small objects from falling in or
being placed in the port 416 and thereby affecting AAV
function.
FIG. 134 is an exploded view of the elbow assembly 5, FIGS. 135-140
are assembled views of the elbow assembly 5, FIGS. 141-147 are
isolated views of the elbow 10, and FIGS. 148-154 are isolated
views of the clip member 200.
FIGS. 155-156 are exploded views illustrating the elbow 10 of FIGS.
134-154 being assembled between a mask frame 440 (via throughhole
442) and a swivel joint 445. FIGS. 157-161 are various views
illustrating the elbow 10 of FIGS. 134-154 connected between the
mask frame 440 and the swivel joint 445. As illustrated, the first
portion 404 of the elbow 10 snap-fits to the mask frame 440, and
the elbow 10 may be removed from the mask frame 440 by pulling
outwards. The swivel joint 445 snap-fits to the second portion 406
of the elbow 10, and the swivel joint 445 may be removed from the
elbow 10 by pulling downwards or levering off. The clip member of
FIGS. 134-154 no longer has lugs to connect it to the elbow, rather
the clip member has a recess. The clip member also has an overhang
portion 437 to make disassembly easier, i.e., the overhang portion
437 provides an edge or finger grip/catch.
3.0 Drop-In AAV Assembly
3.1 First Embodiment
FIGS. 162-164 illustrate an elbow assembly 5 according to yet
another embodiment of the present invention. The elbow assembly
includes a first elbow portion 320, a second elbow portion 325 and
an AAV assembly 15. The AAV assembly may be similar to the AAV
assembly described above.
First elbow portion 320 and second elbow portion 325 are connected
by a locking assembly. The locking assembly may include a one or
more arms 330 having a locking claw 335 that engage with a flange
340. The position of the arms and flange may be interchanged,
although FIG. 162 shows the arms/claws on the first (or upper)
elbow portion, and the flange on the second (or lower) elbow
portion.
The AAV assembly 15 is supported on the second elbow portion 325.
The second elbow portion includes a ledge 345 to support the bottom
of the AAV assembly and a wall 350 to laterally support the AAV
assembly. The wall and the AAV assembly have a generally D-shaped
profile to facilitate alignment. The upper elbow portion includes a
D-shaped recess 355 so that the lower elbow portion can only be
inserted in one orientation. While the AAV assembly is shown to
have a D-shape, it need not have a wedge shape as in the prior
embodiments.
3.2 Second Embodiment
FIGS. 165-168 show a mask assembly 360 according to another
embodiment of the present invention. The mask assembly 360 includes
a full face mask frame 365, an elbow assembly 5, and a swivel joint
370. A portion of an air delivery conduit 375 which is in
communication with a flow generator is also shown.
The elbow assembly 5 as shown in FIGS. 167-168 includes a first
elbow portion 380, a second elbow portion 385 and an AAV assembly
15 positioned therebetween. The first elbow portion 380 includes a
shoulder 390 to support the AAV assembly, while the second elbow
portion includes a channel 395 to receive the AAV assembly. The AAV
assembly and the interfacing portions of the first and second elbow
portions have a unique shape that allows for the correct
orientation of the hinge portion of the flap portion relative to
the port in the elbow. In one example, these portions are generally
D-shaped. The D-shape of the AAV assembly allows it to be assembled
in one of two correct positions (right side up or upside down), as
described above. The side walls of the AAV assembly may be
generally curved as well, as shown in FIG. 168.
As seen in FIG. 167, the first elbow portion 380 includes a port 40
that can be selectively opened when the flap portion of the AAV
assembly has been closed. The port 40 in this example is oriented
towards the mask frame, or on the inside curve of the elbow. The
AAV assembly is oriented to accommodate for the changed location of
the port as well.
3.3 Third Embodiment
FIGS. 169-171 illustrate an elbow assembly 5 according to yet
another embodiment of the present invention. Elbow assembly 5
includes a first elbow portion 396, a second elbow portion 398 and
an AAV assembly 15 sandwiched between the first and second portions
of the elbow. The AAV assembly in this example has a generally
cylindrical base member 70 and a flap portion 45 hinged to an
inside surface of the base member.
The first elbow portion 396 includes a port 40 that can be engaged
by the flap portion 45 of the AAV assembly. The first and second
portions of the elbow are connected via a tongue and groove
arrangement.
3.4 Fourth Embodiment
FIGS. 172 and 173 illustrate another embodiment of an elbow
assembly 5 including an AAV assembly 15 sandwiched between first
and second portions 400, 402 of the elbow. In the illustrated
embodiment, the port 40 protrudes into the elbow. However, the port
40 may have a flat face as illustrated in above described
embodiments.
This embodiment has the additional advantage that the AAV assembly
15 forms an oxygen diverter valve with the lower portion of the
elbow.
4.0 Elbow-to-Frame Interface
The following includes descriptions of mask assemblies including
elbow to frame interfaces or assembly mechanisms according to
several illustrated embodiments of the present invention. In each
of the illustrated embodiments, the mask assembly includes an elbow
that is adapted to be removably connected to a frame via an elbow
to frame assembly mechanism.
The elbow to frame assembly mechanism provides an interface between
the elbow and frame to facilitate assembly and disassembly. In
addition, the elbow to frame assembly mechanism may be structured
to facilitate molding of the elbow and/or frame.
In the illustrated embodiment, the elbow and frame form a part of a
full-face mask. However, aspects of the present invention may be
applicable to other breathing arrangements, e.g., a nasal mask, a
mouth mask, etc. Also, each illustrated embodiment includes
features that may be used with and/or in the other illustrated
embodiments, as would be apparent to those of ordinary skill in the
art.
4.1 First Embodiment
FIGS. 174-185 illustrate an elbow to frame assembly mechanism
according to an embodiment of the present invention. As
illustrated, the elbow 10 includes two snap-fit tabs 450 to connect
the elbow 10 to the mask frame 455 with a snap-fit. Specifically,
each snap-fit tab 450 includes a hook portion 452 that interlocks
with an elbow retaining feature, e.g., annular ring 456, provided
to the mask frame 455. Each snap-fit tab 450 includes external
finger grips 454 to facilitate release of the elbow 10 from the
mask frame 455 by pressing inwards on the external finger grips
454. The elbow retaining feature may be molded in a line of draw,
i.e., easy to mold.
FIGS. 174-179 are exploded views illustrating the elbow 10 being
assembled to the mask frame 455, and FIGS. 180-185 are various
views illustrating the elbow 10 connected to the mask frame 455.
This type of mechanism may be used in conjunction with embodiments
2.8, 2.9, 2.10, and 2.11, for example.
4.2 Second Embodiment
FIGS. 186-203 illustrate an elbow to frame assembly mechanism
according to another embodiment of the present invention. As
illustrated, the mask frame 460 includes an elbow-to-frame adaptor
462 to connect the elbow 10 to the mask frame 460 with a snap-fit.
Specifically, the elbow-to-frame adaptor 462, e.g., constructed of
rigid plastic, is attached to the mask frame 460 with a snap-fit.
The elbow-to-frame adaptor 462 may be removable or permanently
assembled, e.g., ultrasonic welding. The elbow-to-frame adaptor 462
is formed separately from the mask frame 460, e.g., molded as a
separate part, to simplify molding of the mask frame 460. The
elbow-to-frame adaptor 462 may be formed or molded in a different
material from the mask frame 460 for aesthetic purposes and/or in a
different material from the elbow to reduce the chance of squeak
between like materials.
The elbow-to-frame adaptor 462 includes a flanged collar member 464
onto which the elbow 10 can be releasably connected. The elbow 10
is connected to the elbow-to-frame adaptor 462 in a snap-fit manner
as is known from U.S. patent application publication no.
2003/0196656 incorporated herein by reference. The elbow 10 may be
release from the elbow-to-frame adaptor 462 by pressing inwards on
two external finger grips 468 provided to the elbow 10.
The elbow-to-frame adaptor 462 also includes a opening 466 that
accommodates a port cap 470, e.g., formed of flexible silicone,
releasably connected to a port provided to the mask frame 460. The
port cap 470 may be permanently attached to the adaptor 462 via
co-molding, etc., or remain separate.
FIGS. 186-191 are exploded views illustrating the elbow 10, mask
frame 460, elbow-to-frame adaptor 462, and port cap 470, FIGS.
192-197 are partial assembled views illustrating the elbow-to-frame
adaptor 462 connected to the mask frame 460, and FIGS. 198-203 are
various assembled views illustrating the elbow 10 and port cap 470
connected to the mask frame 460.
4.3 Third Embodiment
FIGS. 204-221 illustrate an elbow to frame assembly mechanism
according to another embodiment of the present invention. As
illustrated, an elbow seal 472 is provided to the mask frame 474 to
provide a seal between the elbow 10 and the mask frame 474.
Specifically, the elbow seal 472, e.g., constructed of flexible
silicone, is attached to the collar member of the mask frame 474.
The elbow seal 472 covers air gaps and/or incorporates protrusions
to interlock with gaps 480 in the mask frame 474 and also acts to
reduce any sloppy fit between the mask frame 474 and the elbow 10,
thereby reducing noise or squeak. A port cap 476, e.g., formed of
flexible silicone, is integrated with the elbow seal 472. The port
cap 476 is releasably connected to a port provided to the mask
frame 474. The elbow seal 472 may be co-molded to the elbow or
molded and vibration welded to the elbow if a TPE plastic, for
example.
The collar member of the mask frame 474 includes a castellated rim
that provides flange segments 478 that engage or interface with the
elbow 10. The elbow 10 is connected to the flange segments 478 in a
snap-fit manner as is known from U.S. patent application
publication no. 2003/0196656 incorporated herein by reference.
As best shown in FIGS. 209, 215, and 221, localized gaps 480 are
formed in the mask frame 474 as a result of the molding process.
The localized gaps 480 enable the castellated feature on the collar
member of the mask frame 474 to be molded more easily.
FIGS. 204-209 are exploded views illustrating the elbow 10, mask
frame 474, and elbow seal and integrated port cap 472, 476, FIGS.
210-215 are partial assembled views illustrating the elbow seal and
integrated port cap 472, 476 connected to the mask frame 474, and
FIGS. 216-221 are various assembled views illustrating the elbow 10
connected to the mask frame 474.
In the illustrated embodiment, the elbow seal is provided between
the elbow and the frame. In an alternative embodiment, an over seal
may be provided that seals with an exterior surface of the elbow
and an exterior rib provided to the frame. Thus, the over seal
seals over the elbow and frame. The seal may be integrated,
co-molded, or over-molded to the elbow, for example.
4.4 Fourth Embodiment
FIGS. 222-233 illustrate an elbow to frame assembly mechanism
according to another embodiment of the present invention. As
illustrated, the elbow 10 includes a snap-fit tab 482 on a top
portion thereof to connect the elbow 10 to the mask frame 484 with
a snap-fit. Specifically, the snap-fit tab 482 includes a hook
portion 486 that interlocks with a collar 488 provided to the mask
frame 484. The elbow 10 is pulled outwardly while depressing tab
482 to release the elbow 10 from the mask frame 484. The
elbow-to-frame interface detail or collar 488 may be molded in a
line of draw and with side cores, i.e., relatively easy to mold.
The tab 482 may be used in conjunction with snap-fit tabs described
previously (e.g., see FIGS. 68-89 and 234-251), of which there may
be any suitable number of previously described snap-fit tabs, e.g.,
2-10 tabs.
FIGS. 222-227 are exploded views illustrating the elbow 10 being
assembled to the mask frame 484, and FIGS. 22S-233 are various
views illustrating the elbow 10 connected to the mask frame
484.
4.5 Fifth Embodiment
FIGS. 234-251 illustrate an elbow to frame assembly mechanism
according to another embodiment of the present invention. As
illustrated, the mask frame elbow 10 includes an elbow-to-swivel
adaptor 490 to connect the elbow 10 to a swivel (not shown) with a
snap-fit. Specifically, the elbow-to-swivel adaptor 490, e.g.,
constructed of rigid plastic, includes a snap-fit tab 492 to
connect the adaptor 490 to the elbow 10 with a snap-fit.
Specifically, the snap-fit tab 492 includes a hook portion 494 that
interlocks with an opening 496 provided to the elbow 10. The
snap-fit tab 494 is pushed inwardly to release the adaptor 490 from
the elbow 10. The end of the adaptor includes multiple snap-fit
tabs 498 to connect the adaptor 490 to a swivel. The elbow 10 also
includes multiple snap-fit tabs 500 to connect the elbow 10 to the
mask frame 502 with a snap-fit. In this embodiment, the snap-fit
tabs 500 are a semi-permanent connection and the quick release
connection is via tab 492.
FIGS. 234-239 are exploded views illustrating the elbow 10, mask
frame 502, and elbow-to-swivel adaptor 490, FIGS. 240-245 are
partial assembled views illustrating the elbow 10 connected to the
mask frame 502, and FIGS. 246-251 are various assembled views
illustrating the elbow 10 connected to the mask frame 502 and
elbow-to-swivel adaptor 490.
4.6 Sixth Embodiment
FIGS. 252-269 illustrate an elbow to frame assembly mechanism
according to another embodiment of the present invention. As
illustrated, the mask frame 505 includes an elbow-to-frame adaptor
506 to connect the elbow 10 to the mask frame 505 with a snap-fit.
Specifically, the elbow-to-frame adaptor 506, e.g., constructed of
rigid plastic, is attached to the mask frame 505. The
elbow-to-frame adaptor 506 may be removably attached (e.g.,
snap-fit assembly, bayonet connection), glued, or ultrasonically
welded in place to the mask frame 505. The elbow-to-frame adaptor
506 is formed separately from the mask frame 505, e.g., molded as a
separate part, to simplify molding of the mask frame 505.
The elbow-to-frame adaptor 506 includes a flanged collar member 508
onto which the elbow 10 can be releasably connected. The elbow 10
is connected to the elbow-to-frame adaptor 506 in a snap-fit manner
as is known from U.S. patent application publication no.
2003/0196656 incorporated herein by reference.
FIGS. 252-257 are exploded views illustrating the elbow 10, mask
frame 505, and elbow-to-frame adaptor 506, FIGS. 258-263 are
partial assembled views illustrating the elbow-to-frame adaptor 506
connected to the mask frame 505, and FIGS. 264-269 are various
assembled views illustrating the elbow 10 connected to the mask
frame 505.
4.7 Seventh Embodiment
FIGS. 270-281 illustrate an elbow to frame assembly mechanism
according to another embodiment of the present invention. As
illustrated, the mask frame 510 includes a flanged collar member
512 onto which the elbow 10 can be releasably connected. The elbow
10 is connected to the flanged collar member 512 in a snap-fit
manner as is known from U.S. patent application publication Ser.
No. 10/390,682 incorporated herein by reference. In an embodiment,
the flanged collar member 512 or interface rim is integrally molded
with the mask frame 510 using a 3-part split collar in the
mold.
FIGS. 270-275 are exploded views illustrating the elbow 10 being
assembled to the mask frame 510, and FIGS. 276-281 are various
views illustrating the elbow 10 connected to the mask frame
510.
4.8 Eighth Embodiment
FIGS. 282-299 illustrate an elbow to frame assembly mechanism
according to another embodiment of the present invention. As
illustrated, the mask frame 515 includes an elbow-to-frame adaptor
516 to connect the elbow 10 to the mask frame 515 with a snap-fit.
Specifically, the elbow-to-frame adaptor 516, e.g., constructed of
rigid plastic, is attached to the mask frame 515. In the
illustrated embodiment, the elbow-to-frame adaptor 516 is removably
attached to the mask frame 515 via a bayonet-style fitting. That
is, the adaptor 516 includes tabs 518 that interlock with
respective recesses 520 provided to the mask frame 515. The
elbow-to-frame adaptor 516 is formed separately from the mask frame
515, e.g., molded as a separate part, to simplify molding of the
mask frame 515.
The elbow-to-frame adaptor 516 includes a flanged collar member 522
onto which the elbow 10 can be releasably connected. The elbow 10
is connected to the elbow-to-frame adaptor 516 in a snap-fit manner
as is known from U.S. patent application publication no.
2003/0196656 incorporated herein by reference.
FIGS. 282-287 are exploded views illustrating the elbow 10, mask
frame 515, and elbow-to-frame adaptor 516, FIGS. 288-293 are
partial assembled views illustrating the elbow-to-frame adaptor 516
connected to the mask frame 515, and FIGS. 294-299 are various
assembled views illustrating the elbow 10 connected to the mask
frame 515.
An advantage of the above-described embodiments is that they may be
suitable for multi-patient multi-use (MPMU). That is, the entire
elbow assembly may be sterilized or disinfected as appropriate for
use between different patients. The above-described embodiments
have the advantage of MPMU due to their increased size over known
AAV assemblies and the fact that the elbow, AAV assembly, and clip
member may be pulled apart for cleaning. This is different to other
known designs that are permanently assembly, e.g., Respironics
Comfort Full.
The AAV assemblies 15 are not limited to the shapes and/or sizes
described above. For example, the AAV assemblies 15 may have oval,
rectangular, or other suitable shapes. Also, the elbow slot for
receiving the AAV assembly may have an angle in the range of
20-40.degree. with respect to horizontal, e.g., 30.degree..
Further, the AAV assemblies may be constructed of LSR as well as
other suitable materials, e.g., TPU, TPE.
It will be understood that, in each of the above-described
embodiments, reference to an AAV assembly 15 may include an
integral one-piece structure, or multiple parts that are formed
separately from one another and then interconnected.
While the invention has been described in connection with what are
presently considered to be the most practical and preferred
embodiments, it is to be understood that the invention is not to be
limited to the disclosed embodiments, but on the contrary, is
intended to cover various modifications and equivalent arrangements
included within the spirit and scope of the invention. Also, the
various embodiments described above may be implemented in
conjunction with other embodiments, e.g., aspects of one embodiment
may be combined with aspects of another embodiment to realize yet
other embodiments. In addition, while the invention has particular
application to patients who suffer from OSA, it is to be
appreciated that patients who suffer from other illnesses (e.g.,
congestive heart failure, diabetes, morbid obesity, stroke,
barriatric surgery, etc.) can derive benefit from the above
teachings. Moreover, the above teachings have applicability with
patients and non-patients alike in non-medical applications.
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